Jack JEEP GRAND CHEROKEE 2003 WJ / 2.G Owner's Manual

DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
(1) Check the coolant level and fill as required. DO
NOT install the radiator cap.
(2) Start and operate the engine until it attains
normal operating temperature, then turn the engine
OFF.
(3) Remove the spark plugs.
(4) Remove the oil filler cap.
(5) Remove the air cleaner.(6) Calibrate the tester according to the manufac-
turer's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum and 552 kPa (80 psi) recom-
mended.
(7) Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
Set piston of cylinder to be tested at TDC compres-
sion,While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
Refer to CYLINDER COMBUSTION PRESSURE
LEAKAGE DIAGNOSIS CHART .
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
AIR ESCAPES THROUGH
THROTTLE BODYIntake valve bent, burnt, or not
seated properlyInspect valve and valve seat.
Reface or replace, as necessary.
Inspect valve springs. Replace as
necessary.
AIR ESCAPES THROUGH
TAILPIPEExhaust valve bent, burnt, or not
seated properlyInspect valve and valve seat.
Reface or replace, as necessary.
Inspect valve springs. Replace as
necessary.
AIR ESCAPES THROUGH
RADIATORHead gasket leaking or cracked
cylinder head or blockRemove cylinder head and inspect.
Replace defective part
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERSHead gasket leaking or crack in
cylinder head or block between
adjacent cylindersRemove cylinder head and inspect.
Replace gasket, head, or block as
necessary
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLYStuck or broken piston rings;
cracked piston; worn rings and/or
cylinder wallInspect for broken rings or piston.
Measure ring gap and cylinder
diameter, taper and out-of-round.
Replace defective part as necessary
WJENGINE - 4.7L 9 - 69
ENGINE - 4.7L (Continued)

(32) Disconnect body ground strap at the right side
cowl.
NOTE: It will be necessary to support the transmis-
sion in order to remove the engine.
(33) Position a suitable jack under the transmis-
sion.
(34) Remove the engine mount through bolts.
(35) Raise engine slightly, then remove both left
and right side engine mounts from engine. (Refer to
9 - ENGINE/ENGINE MOUNTING/FRONT MOUNT
- REMOVAL).
(36) Remove engine from the vehicle.
INSTALLATION
(1) Position engine in the vehicle.
(2) Install both left and right side engine mounts
onto engine (Refer to 9 - ENGINE/ENGINE MOUNT-
ING/FRONT MOUNT - INSTALLATION).
(3) Install transmission to engine mounting bolts.
Tighten the bolts to 41 N´m (30 ft. lbs.).(4) Remove jack from under the transmission.
(5) Remove engine lifting fixture special tool 8347
(Fig. 7).
(6) Connect ground straps on the left side of the
engine.
(7) Install power steering pump (Refer to 19 -
STEERING/PUMP - INSTALLATION).
(8) Connect fuel supply line quick connect fitting
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
QUICK CONNECT FITTING - STANDARD PROCE-
DURE).
(9) Connect engine harness at the following points
(Fig. 6):
²Intake Air Temperature (IAT) Sensor
²Idle Air Control (IAC) Motor
²Fuel Injectors
²Throttle Position (TPS) Switch
²Engine Oil Pressure Switch
²Engine Coolant Temperature (ECT) Sensor
²Manifold Absolute Pressure (MAP) Sensor
Fig. 6 Throttle Body Connection Points
1 - THROTTLE BODY
2 - TPS
3 - IAC MOTOR
4 - IAT SENSOR (THREADED TYPE)
5 - MOUNTING SCREWS
Fig. 7 Engine Lifting Fixture Attachment Locations
1 - ATTACHING LOCATION
2 - ADJUSTABLE HOOK
3 - SPECIAL TOOL 8347 ENGINE LIFT FIXTURE
4 - ATTACHING LOCATIONS
WJENGINE - 4.7L 9 - 73
ENGINE - 4.7L (Continued)

(3) Turn engine off and let set for a few minutes
before restarting. Repeat this several times after
engine has reached normal operating temperature.
(4) Low oil pressure.
(5) The oil restrictor in cylinder head gasket or the
oil passage to the cylinder head is plugged with
debris.
(6) Air ingested into oil due to broken or cracked
oil pump pick up.
(7) Worn valve guides.
(8) Rocker arm ears contacting valve spring
retainer.
(9) Rocker arm loose, adjuster stuck or at maxi-
mum extension and still leaves lash in the system.
(10) Oil leak or excessive cam bore wear in cylin-
der head.
(11) Faulty lash adjuster.
a. Check lash adjusters for sponginess while
installed in cylinder head and cam on camshaft at
base circle. Depress part of rocker arm over adjuster.
Normal adjusters should feel very firm. Spongy
adjusters can be bottomed out easily.
b. Remove suspected lash adjusters, and replace.
c. Before installation, make sure adjusters are at
least partially full of oil. This can be verified by little
or no plunger travel when lash adjuster is depressed.
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
²Loss of engine power
²Engine misfiring
²Poor fuel economy
Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50±70%
reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Raise the vehicle on a hoist.
(3) Disconnect the exhaust pipe at the left side
exhaust manifold.
(4) Drain the engine coolant. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(5) Lower the vehicle.
(6) Remove the intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL).
(7) Remove the cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(8) Remove accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(9) Remove the power steering pump and set
aside.
(10) Rotate the crankshaft until the damper tim-
ing mark is aligned with TDC indicator mark (Fig.
9).
WJENGINE - 4.7L 9 - 85
CYLINDER HEAD - LEFT (Continued)

(5) Using special tool 8516 press downward on the
valve spring, install rocker arm (Fig. 28).
(6) Install the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
VALVE SPRINGS
DESCRIPTION
The valve springs are made from high strength
chrome silicon steel. The springs are common for
intake and exhaust applications. The valve spring
seat is integral with the valve stem seal, which is a
positive type seal to control lubrication.
VALVE STEM SEALS
DESCRIPTION
The valve stem seals are made of rubber and incor-
porate an integral steel valve spring seat. The inte-
gral garter spring maintains consistent lubrication
control to the valve stems.
CYLINDER HEAD - RIGHT
DESCRIPTION
DESCRIPTION - CYLINDER HEAD
The cylinder heads are made of an aluminum alloy.
The cylinder head features two valves per cylinder
with pressed in powdered metal valve guides. The
cylinder heads also provide enclosures for the timing
chain drain, necessitating unique left and right cylin-
der heads.
DESCRIPTION - VALVE GUIDES
The valve guides are made of powered metal and
are pressed into the cylinder head. The guides are
not replaceable or serviceable, and valve guide ream-
ing is not recommended. If the guides are worn
beyond acceptable limits, replace the cylinder heads.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
²Loss of engine power
²Engine misfiring
²Poor fuel economy
Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50±70%
reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
Fig. 28 Rocker ArmÐRemoval
1 - CAMSHAFT
2 - SPECIAL TOOL 8516
WJENGINE - 4.7L 9 - 97
ROCKER ARM / ADJUSTER ASSEMBLY (Continued)

STRUCTURAL COVER
DESCRIPTION
The structural dust cover is made of die cast alu-
minum and joins the lower half of the transmission
bell housing to the engine bedplate.
OPERATION
The structural cover provides additional power-
train stiffness and reduces noise and vibration.
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the left hand exhaust pipe from
exhaust manifold.
(3) Loosen the right hand exhaust manifold-to-ex-
haust pipe retaining bolts.
(4) Remove the eight bolts retaining structural
cover (Fig. 82) in the sequence shown.
(5) Pivot the exhaust pipe downward and remove
the structural cover.
INSTALLATION
CAUTION: The structural cover must be installed as
described in the following steps. Failure to do so
will cause severe damage to the cover.
(1) Position the structural cover in the vehicle.
(2) Install all four bolts retaining the cover-to-en-
gine. DO NOT tighten the bolts at this time.
(3) Install the four cover-to-transmission bolts. Do
NOT tighten at this time.CAUTION: The structural cover must be held tightly
against both the engine and the transmission bell
housing during tightening sequence. Failure to do
so may cause damage to the cover.
(4) Starting with the two rear cover-to-engine
bolts, tighten bolts (1) (Fig. 83) to 54 N´m (40 ft. lbs.),
then tighten bolts (2) (Fig. 83) and (3) to 54 N´m ( 40
ft. lbs.) in the sequence shown.
(5) Install the exhaust pipe on left hand exhaust
manifold.
(6) Tighten exhaust manifold-to-exhaust pipe
retaining bolts to 20±26 N´m (15±20 ft. lbs.).
FRONT MOUNT
REMOVAL
(1) Disconnect the negative cable from the battery.
CAUTION: Remove the fan blade, fan clutch and fan
shroud before raising engine. Failure to do so may
cause damage to the fan blade, fan clutch and fan
shroud.
(2) Remove the engine oil filter (Refer to 9 -
ENGINE/LUBRICATION/OIL FILTER - REMOVAL).
(3) Support the engine with a suitable jack and a
block of wood across the full width of the engine oil
pan.
Fig. 82 Structural Cover
Fig. 83 Structural Cover
9 - 124 ENGINE - 4.7LWJ

(4) Remove the four cylinder block-to-insulator
mount bolts and the nut form the engine insulator
mount through bolt (Fig. 84) (Fig. 85)
(5) Using the jack, raise the engine high enough to
remove the engine insulator mount through bolt and
the insulator mount.
INSTALLATION
(1) Position the insulator mount and install the
insulator mount through bolt.
(2) Lower the engine until the four cylinder block-
to-insulator mount bolts can be installed.
(3) Remove the jack and block of wood.
(4) Torque the cylinder block-to-insulator mount
bolts to 61N´m ( 45 ft. lbs.).
(5) Install and torque the through bolt retaining
nut to 61N´m (45 ft. lbs.).
REAR MOUNT
REMOVAL
(1) Raise vehicle on hoist.
(2) Using a suitable jack, support transmission.
(3) Remove the lock nut from the insulator mount
through bolt and the four insulator-to-transmission
mounting bolts.
(4) Raise the transmission enough to remove the
through bolt and insulator mount (Fig. 86) (Fig. 87).
Fig. 84 Engine Insulator Mount 4.7 LEFT
1 - NUT
2 - BOLT
Fig. 85 Engine Insulator Mount 4.7 Right
1 - NUT
2 - BOLT
WJENGINE - 4.7L 9 - 125
FRONT MOUNT (Continued)

ITEM DESCRIPTION TORQUE
1 NUT 45 N´m
(Qty 1) (33 ft. lbs)
2 BOLT 46 N´m
(Qty 4) (34 ft. lbs.)
3 BOLT 68 N´m
(Qty 2 Per
Side)(50 ft. lbs.)
4 BOLT 46 N´m
(Qty 2 Per
Side)(34 ft. lbs.)
5 BOLT 46 N´m
(Qty 4) (34 ft. lbs.)
INSTALLATION
(1) Position the insulator mount and install the
through bolt.
(2) Lower the transmission enough to install the
four insulator-to-transmission mounting bolts. Torque
the bolts to 46N´m (34 ft. lbs.).
(3) Install the through bolt lock nut. Torque nut to
68N´m (50 ft. lbs.).
(4) Remove jack, lower vehicle.
LUBRICATION
DESCRIPTION
The lubrication system (Fig. 88) is a full flow fil-
tration pressure feed type.
OPERATION
Oil from the oil pan is pumped by a gerotor type oil
pump directly mounted to the crankshaft nose. Oil
pressure is controlled by a relief valve mounted
inside the oil pump housing. For lubrication flow
refer to (Fig. 88).
The camshaft exhaust valve lobes and rocker arms
are lubricated through a small hole in the rocker
arm; oil flows through the lash adjuster then through
the rocker arm and onto the camshaft lobe. Due to
the orentation of the rocker arm, the camshaft intake
lobes are not lubed in the same manner as the
exhaust lobes. The intake lobes are lubed through
internal passages in the camshaft. Oil flows through
a bore in the number 3 camshaft bearing bore, and
as the camshaft turns, a hole in the camshaft aligns
with the hole in the camshaft bore allowing engine
oil to enter the camshaft tube. The oil then exits
through 1.6mm (0.063 in.) holes drilled into the
intake lobes, lubricating the lobes and the rocker
arms.
Fig. 86 Engine Rear MountÐ4X2
Fig. 87 Engine Rear MountÐ4X4
9 - 126 ENGINE - 4.7LWJ
REAR MOUNT (Continued)

(14) Install air tube (or duct) at top of throttle
body.
(15) Install fuel tank cap.
(16) Connect negative battery cable to battery.
(17) Start engine and check for fuel leaks.
FUEL TANK
DESCRIPTION
The fuel tank is constructed of a plastic material.
Its main functions are for fuel storage and for place-
ment of the fuel pump module and certain ORVR
components.
OPERATION
All models pass a full 360 degree rollover test
without fuel leakage. To accomplish this, fuel and
vapor flow controls are required for all fuel tank con-
nections.
A fuel tank check valve(s) is mounted into the top
of the fuel tank (or pump module). Refer to Fuel
Tank Check Valve for additional information.
An evaporation control system is connected to the
check valve(s) to reduce emissions of fuel vapors into
the atmosphere. When fuel evaporates from the fuel
tank, vapors pass through vent hoses or tubes to a
charcoal canister where they are temporarily held.
When the engine is running, the vapors are drawn
into the intake manifold. Certain models are also
equipped with a self-diagnosing system using a Leak
Detection Pump (LDP). Refer to Emission Control
System for additional information.
Refer to ORVR for On-Board Refueling Vapor
Recovery system information.
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH ENGINE OFF.
PRESSURE MUST BE RELEASED BEFORE SERVIC-
ING FUEL TANK.
Two different procedures may be used to drain fuel
tank (through ORVR control valve opening at top of
fuel tank, or using DRB scan tool). The quickest is
draining through ORVR control valve opening at top
of fuel tank (Fig. 26).
As an alternative procedure, the electric fuel pump
may be activated allowing tank to be drained at fuel
rail connection. Refer to DRB scan tool for fuel pump
activation procedures. Before disconnecting fuel line
at fuel rail, release fuel pressure. Refer to the Fuel
System Pressure Release Procedure for procedures.
Attach end of Special Adapter Hose Tool number
6539 at fuel rail disconnection. Position opposite end
of 6539 to an approved gasoline draining station.Activate fuel pump with DRB and drain tank until
empty.
If electric fuel pump is not operating, tankMUST
be drained through ORVR control valve opening at
top of fuel tank (Fig. 26).
(1) Release fuel system pressure. Refer to Fuel
System Pressure Release Procedure.
(2) Disconnect negative battery cable at battery.
(3) Raise and support vehicle.
(4) Remove left rear wheel/tire.
CAUTION: HANDLE EVAP, LDP AND ORVR VAPOR /
VACUUM LINES VERY CAREFULLY. THESE LINES
AND HOSES MUST BE FIRMLY CONNECTED.
CHECK THE VAPOR/VACUUM LINES AT THE LDP,
LDP FILTER, EVAP CANISTER, EVAP CANISTER
PURGE SOLENOID AND ORVR COMPONENTS FOR
DAMAGE OR LEAKS. IF A LEAK IS PRESENT, A
DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.
(5) Clean top of fuel tank at ORVR control valve
(Fig. 26) or (Fig. 27).
(6) Press release tab in direction of arrow in (Fig.
27) and remove ORVR control valve lock ring
(counter-clockwise). Lift up ORVR control slightly.
Using an approved gasoline draining station, drain
tank until empty through this opening.
(7) Remove stone shield behind left/rear wheel
(Fig. 28). Drill out plastic rivets for removal.
(8) Remove 3 LDP mounting bolts (Fig. 29).
(9) Remove support bracket brace bolt (Fig. 30).
(10) Loosen, but do not remove 2 support bracket
nuts at frame rail (Fig. 29).
(11) To separate and lower front section of two-
piece support bracket, remove 3 attaching bolts on
bottom of support bracket (Fig. 30). While lowering
support bracket, disconnect LDP wiring clip (Fig. 31).
(12) Remove hose clamp (Fig. 32) and remove fuel
fill hose from fuel fill tube.
(13) Cut and discard tie wrap from axle vent hose
(Fig. 32).
(14) Disconnect fuel vent hose from fuel vent tube
(Fig. 32).
(15) Disconnect ORVR hose elbow (Fig. 33) at top
of EVAP canister.
(16) Place hydraulic jack to bottom of fuel tank.
(17) Remove fuel tank-to-rear bumper fascia clips
(Fig. 34).
(18) Remove fuel tank heat shield mounting bolts
(Fig. 35).
CAUTION: To protect fuel tank from exhaust heat,
shield must re-installed after tank installation.
WARNING: PLACE SHOP TOWEL AROUND FUEL
LINES TO CATCH ANY EXCESS FUEL.
WJFUEL DELIVERY 14 - 19
FUEL RAIL (Continued)

(19) Disconnect fuel return line at fuel filter/fuel
pressure regulator (Fig. 36). Refer to Quick-Connect
Fittings for procedures.
(20) Disconnect fuel pressure line at fuel filter/fuel
pressure regulator (Fig. 36). Refer to Quick-Connect
Fittings for procedures.
(21) Disconnect EVAP canister vent line near front
of tank (Fig. 36).
(22) Disconnect fuel pump module electrical con-
nector (pigtail harness) near front of tank (Fig. 36).
Harness connector is clipped to body.
(23) Remove left / front tank support bracket bolt
at frame (Fig. 37).
(24)WITHOUT TRAILER HITCH:Remove tank-
to-frame mounting bolts (Fig. 39). Remove rear tank
support bracket bolts at frame (Fig. 38). Carefully
lower tank until clear of vehicle. Place tank on floor.
(25)WITH TRAILER HITCH:Remove tank /
hitch mounting bolts (Fig. 40). Carefully lower tank
until clear of vehicle. Place tank on floor.
(26) If necessary, separate skid plate from fuel
tank by removing 2 fuel tank strap nuts (Fig. 39) and
remove 2 tank straps.
(27) If fuel pump module removal is necessary,
refer to Fuel Pump Module Removal/Installation.
(28) If hoses are to be removed at fuel tank end,
note painted alignment (indexing) markings on
hoses, and molded indexing tangs on tank before
removal. Remove hoses.
(29) If necessary, remove 3 fuel filler tube assem-
bly mounting bolts (Fig. 41) and remove fuel filler
tube.
INSTALLATION
CAUTION: HANDLE EVAP, LDP AND ORVR VAPOR /
VACUUM LINES VERY CAREFULLY. THESE LINES
AND HOSES MUST BE FIRMLY CONNECTED.
CHECK THE VAPOR/VACUUM LINES AT THE LDP,
LDP FILTER, EVAP CANISTER, EVAP CANISTER
PURGE SOLENOID AND ORVR COMPONENTS FOR
DAMAGE OR LEAKS. IF A LEAK IS PRESENT, A
DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.
(1) If necessary, position fuel filler tube assembly
to body. Install 3 bolts and tighten to 2 N´m (15 in.
lbs.) torque.
(2) If necessary, connect quick-connect fittings to
fuel pump module.
(3) If fuel pump module is being installed, refer to
Fuel Pump Module Removal/Installation.
(4) Install fuel fill/vent hoses to tank fittings. To
prevent hoses from kinking, rotate each hose until
painted indexing mark on hose is aligned to molded
indexing tang on tank.
(5) Install hose clamps to hoses. Refer to Torque
Specifications.(6) If necessary, position fuel tank into skid plate.
Install 2 tank straps and 2 strap nuts (Fig. 39). Refer
to Torque Specifications.
(7) Position fuel tank / skid plate assembly to
hydraulic jack.
(8) Raise tank into position to frame.
(9)WITH TRAILER HITCH:Position trailer
hitch and tow hooks (Fig. 40) to bottom of fuel tank.
Install bolts and nuts loosely.
(10)WITHOUT TRAILER HITCH:Install 2 rear
tank support brackets and bolts (Fig. 38). Install
tank-to-frame bolts. Do not tighten bolts / nuts at
this time.
(11) Install 1 left / front tank support bracket and
bolts / nuts (Fig. 37). Do not tighten bolts / nuts at
this time.
(12) Be sure fuel tank is properly aligned to frame
and body. Tighten all tank, tow hook and trailer
hitch bolts / nuts except for 3 support brackets.
Tighten all 3 (2 rear and 1 left / front) support
bracket bolts / nuts last. Refer to Torque Specifica-
tions.
(13)
(14) Connect fuel pump module pigtail harness
electrical connector near front of tank.
(15) Connect both fuel lines to fuel filter/fuel pres-
sure regulator. Refer to Quick-Connect Fittings for
procedures.
(16) Connect EVAP hose near front of tank.
(17) Position rear axle vent hose and install new
tie strap (Fig. 32).
(18) Install heat shield nuts / bolts (Fig. 35). Refer
to Torque Specifications.
(19) Connect ORVR hose elbow (Fig. 33) to top of
EVAP canister.
(20) Connect fuel vent hose to fuel vent tube (Fig.
32).
(21) Install fuel fill hose and clamp to fuel fill tube
(Fig. 32).
(22) Install 3 LDP mounting bolts (Fig. 29).
(23) While raising support bracket, connect LDP
wiring clip (Fig. 31). Install front section of two-piece
support bracket to rear section with 3 attaching bolts
located on bottom of support bracket (Fig. 30).
(24) Install support bracket brace bolt (Fig. 30).
(25) Tighten 2 support bracket nuts at frame rail
(Fig. 29).
(26) Install fuel tank-to-rear bumper fascia clips
(Fig. 34).
(27) Using new plastic rivets, install stone shield
behind left/rear wheel (Fig. 28).
(28) Install left rear wheel/tire.
(29) Lower vehicle and connect negative battery
cable to battery.
(30) Fill tank with fuel and check for leaks.
14 - 20 FUEL DELIVERYWJ
FUEL TANK (Continued)

(17) Disconnect throttle valve cable from transmis-
sion bracket and throttle valve lever (Fig. 15).
(18) Disconnect transfer case shift cable from the
transfer case shift lever (Fig. 16).
(19) Remove the clip securing the transfer case
shift cable into the cable support bracket.
(20) Disconnect transmission fluid cooler lines at
transmission fittings and clips.
(21) Support rear of engine with safety stand or
jack.(22) Raise transmission slightly with service jack
to relieve load on crossmember and supports.
(23) Remove bolts securing rear support and cush-
ion to transmission and crossmember (Fig. 17).
(24) Remove bolts attaching crossmember to frame
and remove crossmember.
(25) Remove transfer case (Fig. 18) and (Fig. 19).
Fig. 15 Throttle Valve Cable
1 - THROTTLE VALVE CABLE
2 - THROTTLE VALVE LEVER
3 - THROTTLE BODY
Fig. 16 Transfer Case Shift Cable
1 - TRANSFER CASE SHIFT LEVER
2 - TRANSFER CASE SHIFT CABLE
Fig. 17 Rear Transmission Crossmember
1 - CROSSMEMBER
2 - REAR TRANSMISSION MOUNT
Fig. 18 Remove NV247 Transfer Case
1 - NV247 TRANSFER CASE
21 - 28 AUTOMATIC TRANSMISSION - 42REWJ
AUTOMATIC TRANSMISSION - 42RE (Continued)